Sanitization of an article using in situ electrolysis

ABSTRACT

A system, comprising: a chlorine source in form of an electrolysis unit to generate an in-situ generated active chlorine; wherein a concentration of perchlorate is not more than half of a concentration of chlorate; and pH of a fluid containing in-situ generated active chlorine is more than 7.4; a buffer tank to store a concentrate of in-situ generated active chlorine as a free available chlorine (FAC); a fluid distribution system to supply FAC in form of an in-use fluid to the cabinet; wherein the system is configured to clean and disinfect an article with the fluid while complying with national and international standards for food safety, operator&#39;s safety and regulatory requirements regarding the use of biocides.

FIELD OF THE INVENTION

This invention relates to a method and a system to sanitize the articleusing in situ electrolysis.

BACKGROUND OF INVENTION

The electrolysis of alkali chloride solutions by means of electrolyticcells has been a well-known practice for decades, most importantly forindustrial-scale manufacturing of chlorine bleach, with the desiredbyproduct of sodium hydroxide and the option for subsequent burning ofchlorine gas with hydrogen gas formed at the cathode, to obtainhydrochloric acid.

Small-scale electrolytic devices have become more and more popular overthe last approximately 20 years, mainly a result of technologicalprogress in the field of affordable but still reliable process control.

Smaller-scale chlorine electrolysis devices, which are operated on thesite of chlorine use are available as well. Apart from some rareapplications like waste-water treatment, chlorine from these devices isnormally used for biocidal purposes, to control undesired or harmfulmicroorganisms.

Low-chlorate electrolysis devices are also readily available, typicallywith separated electrolysis half-cells and an opportunity to withdraw orpartly re-circulate both analyte and catholyte.

An even lower specific chlorate level can be achieved, but afterscheduled process interruptions of up to 72 hours (for example overweekends), the situation in the batch tank holding the concentrate(which is usually level-operated and thereby guarantees a swift restartof the system after a longer interruption) might no longer be compliantwith the maximum tolerable specific chlorate content on food contactmaterials treated without rinsing, and consecutively in processedfood/feed.

The decomposition of in-situ generated chlorine solution is described tousually take place very rapidly, resulting in a loss of more than 50% ofthe available chlorine over a period of several days, accompanied bydramatically increasing chlorate concentrations.

These devices require expensive maintenance costs to maintain anultra-low chlorate concentration. The split-cell devices are notpracticable for de-centralized use, e.g. in very large industrial-scaleapplications or in horticulture.

It must be noted that a later adjustment of the pH of the electrolyteconcentrate, or dilution is not permitted in the European Union—since itwould not be covered by applicable drinking water specifications andtreatment process requirements.

Further, regarding biocidal use of chlorine, the ones that are relatedto potential or incidental food contact are most important such as butnot limited to Industrial food processing, animal husbandry,horticulture etc.

The active substance chlorine has been assessed for local effects only.The undissociated chlorine compound of the same oxidation state such ashypochlorous acid exhibits a significant vapor pressure which must beconsidered for inhalation hazard and risk for all biocidal uses. Thepresent devices operating at a pH <7.5 would lead to an unacceptableexposure of operators to hypochlorous acid during the application, suchas spraying, regardless of whether in an enclosure (cabinet) or an openspraying nozzle.

Larger-scale electrolytic devices are typically used for manufacturingstorage stable aqueous solution with low chlorine content (typically <1g/L FAC) and a pH below 7.4, which leads to the absolute predominance ofundissociated hypochlorous acid. These solutions are usuallymanufactured and sold in the initial concentration range of 250 to 650mg/L of active chlorine and are used in most cases without furtherdilution.

On the other hand, byproducts of concern in the context of food contactapplications should also be observed carefully.

Chlorate, being a well-known pesticide is under scrutiny from regulatorsworldwide.

Perchlorate is the highest oxidized chlorine species possible. In fact,some of the systemic endpoints for chlorate have been taken fromperchlorate animal studies. It is a well-known endocrine disruptor, aniodine antagonist, and is already under observation from someregulators, for example, the German Federal Risk Assessment Agency(BfR—Bundesinstitut für Risikobewertung).

At least in Europe, endocrine disrupting properties of substances areconsidered to be of non-threshold effects, which might end up in azero-tolerance regulatory policy towards perchlorate residues in food orfeeding stuff. Perchlorate is a non-threshold thyroid endocrinedisruptor. According to European guidelines, compliance shall beconfirmed by modelling dietary exposure for consumers (includingtoddlers) and comparison of (also combined) exposure with chlorateMaximum Residue Level (MRL) or Assigned Exposure Limit (AEL).

The available European food safety authority (EFSA)/European chemicalsagency (ECHA) Guidance and bespoke models are required for assessment ofdietary exposure. Non-compliance leads to a non-authorization decisionand subsequent loss in marketability. Similar regulatory regimes existin other countries also such as United States of America.

As a standard procedure in the United States, it is not allowed totreat/disinfect food with chlorine (FAC) solutions in the USA.

There are also massive concerns in some parts of the world, for example,in the European Union, regarding chlorine in contact with food.

This led to the requirement of a post-rinsing of the food material withdrinking water in case high chlorine concentrations was used todisinfect tools that came in contact with food. It therefore required tocompare the maximum amount of chlorine transferred e.g., a full carcassrinsed off with drinking water at the given maximum permitted drinkingwater chlorine concentration (a common and allowed practice), with theamount of chlorine transferred to a comparable piece of food (comparablein terms of surface to mass ratio) by the disinfected (and not rinsed)cutting tool.

These considerations resulted in the development of the most common useof a hot water/disinfectant bath. The tools to be disinfected are simplyinserted/soaked in the hot water bath. This risks re-contamination withcollected soil removed from treated surfaces that subsequently meets alldevices treated in the same bath. The hot bath does not have beneficialeffect of mechanical action in a spraying environment.

Further, in the hot water system, knives and other instruments usedbetween the processing of the various carcasses must be disinfected at82° C. hot water or an alternative system with at least similar effect.During this process, blood, fat, denatured protein, and lime accumulatedon the blade producing foul smell and overall poor hygiene.

Economically also the hot water system has disadvantages. It requireshigh (almost double) volume of water, high energy demand for hot watersupply, high maintenance costs, occupational safety concerns, scaldingconcerns, dulling of the blade due to fouling, and limescale build-up onthe blade.

Disinfectants like lactic acid, peracetic acid, peroctanoic acid, etc.have been applied as disinfectants for tools at the concentration of0.16% vol. Problems with such systems are that they are inefficient withbeef because beef fat residues settle on the knife and the smell isfoul, which is not acceptable to an operator.

Further, there is also a danger with corrosion due to highconcentrations and long-term contact with the disinfectant in theslaughtering system.

In case of actual in-situ chlorine generation devices, which produce theactive substance more or less in real time, there is less opportunity toinclude advanced technical features, due to the decentralized deploymentof larger numbers of small-scale electrolysis units.

While there are a lot of opportunities to control the process (in termsof electrolysis parameters, pH, conductivity, buffer capacity of feedelectrolyte and so on), when using electrolysis for the production ofstable storage chlorine solutions at a pH of lower than 7.4, completelydifferent conditions and system requirements exist in the field ofactual in-situ generation of active chlorine for biocidal purposes. Ithas been observed that there is increase in chlorate content duringlong-term storage, up to 2 years, depending on the predominant pathwayof chlorine decomposition, either by disproportionation into chloriteand chlorate, or by reductive decomposition into chloride with oxygenrelease.

Therefore, there is a long felt need for a process and system thereof,that is cost effective, easy to operate, less operator's exposure toharmful byproducts and efficient in disinfection.

SUMMARY OF INVENTION

In one embodiment, a system, comprising: a variable level-controlledchlorine batch tank; an electrolysis unit to generate an in-situgenerated active chlorine; wherein a concentration of perchlorate is notmore than half of a concentration of chlorate; and pH of a fluidcontaining in-situ generated active chlorine is more than 7.4; a buffertank to store a concentrate of in-situ generated active chlorine as afree available chlorine (FAC); a cabinet; a fluid distribution system tosupply FAC in the form of an in-use fluid to the cabinet; whereintemperature of the in-use fluid is less than 82° C.; wherein the systemis configured to clean and disinfect an article with the fluid.

In an embodiment, pH of the system is about 7.5 to about 8.5.

In an embodiment, the concentration of perchlorate is about 0.01 mg/L.

In an embodiment, the cabinet is configured to place an article andexpose the article to the in-use fluid.

In an embodiment, exposure time for the article is about less than 1minute.

In an embodiment, the pH is achieved without use of a pH modifier toalter pH of a feed electrolyte.

In an embodiment, the pH is achieved without use of a pH modifier toalter pH of a chlorine concentrate.

In an embodiment, the pH is achieved due to presence of more than 50 Mol% of hypochlorite ion.

In an embodiment, the cabinet further comprises a fluid spraying nozzle.

In an embodiment, the temperature of the in-use fluid is in a range ofabout 30° C. to about 82° C.

In an embodiment, the temperature of the in-use fluid is less than orequal to 45° C.

In an embodiment, the cabinet comprises rotating brushes.

In an embodiment, a concentration of the FAC in the buffer is about 9g/L, (calculated as Cl2).

In an embodiment, wherein the cleaning step fluid and the disinfectingstep fluid are different.

In an embodiment, the system further comprises a diluting unit.

In an embodiment, the system is configured to reduce a microbialcontamination less than a hot water basin system.

In an embodiment, the system is configured to reduce the microbialcontaminant on the article to less than 1 CFU/cm².

In an embodiment, the system has application in a slaughterhouse.

In an embodiment, the article is a knife.

In an embodiment, the system is a single knife technology.

In an embodiment, the system could be used for a multiple knifetechnology (for example: two-knife technology).

BRIEF DESCRIPTION OF THE FIGURES

The patent or application contains at least one drawing executed incolor. Copies of this patent or patent application, withdrawing(s)/figure(s), will be provided by the Office upon request andpayment of the necessary fee.

The figures are furnished with the application to understand theinvention sought to be patented. The figures shall not be construed asthe only way to perform the invention.

FIG. 1 provides a view of the cabinet and chamber and article before(FIG. 1A) and after the pre-rinsing/disinfection of an article, acutting tool (FIG. 1B). Chamber produces in-situ and effectiveconcentration of the product to be used for disinfection of tools suchas knife, the cabinet is the portion that allows knife to be insertedinside the chamber and placed for the disinfection process.

FIG. 2 shows an evaluation of contact samples after disinfection of thecutting tools with the in-situ chlorine system in comparison to 82° C.Sample rate is 50. Bar 1 shows CFU/cm², cfu/cm², KBE/g (KBE/g is aGerman translation of CFU/cm²) measured on knife in contact with beefblood after disinfection by the in-situ system; Bar 3 CFU/cm² measuredon knife used in cutting beef cattle fat after disinfection by thein-situ chlorine system; Bar 5 shows CFU/cm² measured on knife used incutting pork after disinfection by the in-situ chlorine system; Bar 7shows CFU/cm² measured on knife used in cutting pork belly fat afterdisinfection by the in-situ chlorine system.

FIG. 3 shows an evaluation of contact samples after disinfection of thecutting tools with the 82° C. method. Sample rate is 50. 2=CFU/cm²measured on knife in contact with beef blood after disinfection by the82° C. method; 4=CFU/cm² measured on knife used in cutting beef cattlefat after disinfection by the 82° C. method; 6=CFU/cm² measured on knifeused in cutting pork after disinfection by the 82° C. method; 8=CFU/cm²measured on knife used in cutting pork belly fat after disinfection bythe 82° C. method.

FIG. 4 provides a picture of a knife after being disinfected in a hotwater basin in the 82° C. method.

FIG. 5 provides a picture of a knife after being disinfected using thedisclosed present invention.

FIG. 6 provides arrangement of the system according to one embodiment ofthe present invention. Installation of ECA Generator; ‘N’ is anelectrolysis unit, ‘M’ is a reservoir of a salt (Brine tank), ‘L’ is astorage tank for in-situ chlorine produced in the electrolysis. In anembodiment, L Storage tank FAC solution 9.0 gr/ltr

FIG. 7 provides a chamber to insert knife for sanitization according toone embodiment of this invention.

FIG. 8 shows effect of pH on proportion of chlorine in water. Greencolour represents Cl2, blue colour represents hypochlorous acid (HOCl)and red colour represents hypochlorite ion OCl-1. It providesrelationship between pH and proportion of chlorine in water. At pH of7.4 and more, hypochlorite ion is dominant chorine species, whereas atpH less than 7 hypochlorous acid (HOCl) is dominant.

FIG. 9 provides a line drawing of a system providing information onbrine preparation, pre-dilution, electrolysis device, buffer tank withcontrols, post-dilution distributing lines to e.g. cabinet or spraynozzle in a greenhouse etc. Different components of the system areindicated as: (1) for product metering pump (optional to be provided onsite); (2) for pressure meter for potable water; (3) for flow meter forproduct from the cells; (4) for the flow meter softened water to thecells; (5) hypocells; (6) cartridge filler for potable water; (6)collecting pan; (7) collection pan; (8) liquid sensor for collectingpan; (9) air filter; (10) air flow sensor; (11) solenoid valve forsoftened water; (12) Control valve for softened water; (13) sampling tapfor softened water; (14) softener; (15) brine metering pump; (16)temperature sensor for diluted brine to the cells; (17) temperaturesensor for product to the cells ventilator; (18) ventilator; (19) floatvalve for brine storage tank (level controlled); (20) brine storage tank(with sodium chloride); (21) product storage tank, internal enclosedroom system; A-potable water; B-softened water; C-saturated brine;D-Diluted brine; E-Hydrogen; F-product; G-Air; and H-Diluted hydrogen.[Ref: Assembly and operating instructions; Chlorine Electrolysis System;CHLORINSITU® IIa; ProMinent®]

FIG. 10 provides Inline dosing system for chlorine water supply to sprayapplication.

DETAILED DESCRIPTION Definitions and General Techniques

For simplicity and clarity of illustration, the figures illustrate thegeneral manner of construction. Descriptions and details of well-knownfeatures and techniques may be omitted to avoid unnecessarily obscuringthe present disclosure. Additionally, elements in the figures are notnecessarily drawn to scale. For example, the dimensions of some of theelements in the figures may be exaggerated relative to other elements tohelp improve understanding of embodiments of the present disclosure. Thesame reference numerals in different figures denotes the same elements.

The terms “first”, “second”, “third”, “fourth”, and the like in thedescription and in the claims, if any, are used for distinguishingbetween similar elements and not necessarily for describing a particularsequential or chronological order. It is to be understood that the termsso used are interchangeable under appropriate circumstances such thatthe embodiments described herein are, for example, capable of operationin sequences other than those illustrated or otherwise described herein.Furthermore, the terms “include” and “have” and any variations thereof,are intended to cover a non-exclusive inclusion, such that a process,method, system, article, device, or apparatus that comprises a list ofelements is not necessarily limited to those elements, but may includeother elements not expressly listed or inherent to such process, method,system, article, device, or apparatus.

The terms “left”, “right”, “front”, “back”, “top”, “bottom”, “over”,“under”, and the like in the description and in the claims, if any, areused for descriptive purposes and not necessarily for describingpermanent relative positions. It is to be understood that the terms soused are interchangeable under appropriate circumstances, such that theembodiments of the apparatus, methods, and/or articles of manufacturedescribed herein are, for example, capable of operation in otherorientations than those illustrated or otherwise described herein.

No element, act, or instruction used herein should be construed ascritical or essential unless explicitly described as such. Also, as usedherein, the articles “a” and “an” are intended to include items and maybe used interchangeably with “one or more”. Furthermore, as used herein,the term “set” is intended to include items (e.g., related items,unrelated items, a combination of related items and unrelated items,etc.), and may be used interchangeably with “one or more”. Where onlyone item is intended, the term “one” or similar language is used. Also,as used herein, the terms “has”, “have”, “having”, and the like areintended to be open-ended terms. Further, the phrase “based on” isintended to mean “based, at least in part, on” unless explicitly statedotherwise.

The terms “couple”, “coupled”, “couples”, “coupling”, and the likeshould be broadly understood to refer to connecting two or more elementsmechanically and/or otherwise. Two or more electrical elements may beelectrically coupled together, but not be mechanically, or otherwise,coupled together. Coupling may be for any length of time, e.g.,permanent or semi-permanent or only for an instant. “Electricalcoupling” and the like should be broadly understood and includeselectrical coupling of all types. The absence of the word “removably”,“removable”, and the like near the word “coupled”, and the like, doesnot mean that the coupling, etc. in question is or is not removable.

As defined herein, two or more elements are “integral” if they arecomprised of the same piece of material. As defined herein, two or moreelements are “non-integral” if each is comprised of a different piece ofmaterial.

As defined herein, “real-time” can, in some embodiments, be defined withrespect to operations carried out as soon as practically possible uponoccurrence of a triggering event. A triggering event can include receiptof data necessary to execute a task or to otherwise process information.Because of delays inherent in transmission and/or in computing speeds,the term “real time” encompasses operations that occur in “near” realtime or somewhat delayed from a triggering event. In a number ofembodiments, “real time” can mean real time less a time delay forprocessing (e.g., determining) and/or transmitting data. The particulartime delay can vary depending on the type and/or amount of the data, theprocessing speeds of the hardware, the transmission capability of thecommunication hardware, the transmission distance, etc. However, in manyembodiments, the time delay can be less than approximately one second,two seconds, five seconds, or ten seconds.

The present invention may be embodied in other specific forms withoutdeparting from its spirit or characteristics. The described embodimentsare to be considered in all respects only as illustrative and notrestrictive. The scope of the invention is, therefore, indicated by theappended claims rather than by the foregoing description. All changeswhich come within the meaning and range of equivalency of the claims areto be embraced within their scope.

As defined herein, “approximately” or “about” can, in some embodiments,mean within plus or minus ten percent of the stated value. In otherembodiments, “approximately” can mean within plus or minus five percentof the stated value. In further embodiments, “approximately” can meanwithin plus or minus three percent of the stated value. In yet otherembodiments, “approximately” can mean within plus or minus one percentof the stated value.

Unless otherwise defined herein, scientific and technical terms used inconnection with the present invention shall have the meanings that arecommonly understood by those of ordinary skill in the art. Further,unless otherwise required by context, singular terms shall includepluralities and plural terms shall include the singular. Generally,nomenclatures used in connection with, and techniques of, healthmonitoring described herein are those well-known and commonly used inthe art.

The methods and techniques of the present invention are generallyperformed according to conventional methods well known in the art, andas described in various general and more specific references throughoutthe present specification unless otherwise indicated. The nomenclaturesused in connection with, and the procedures and techniques of,embodiments herein, and other related fields described herein, are thosewell known and commonly used in the art.

The following terms and phrases, unless otherwise indicated, shall beunderstood to have the following meanings.

The term “chlorine source” is defined as a source that can providechlorine or species of chlorine during electrolysis. The chlorine sourcecould be all possible salt of chlorine which produce chlorine orchlorine species, for example sodium chloride solution (brine) orpotassium chloride produce chlorine during electrolysis. The chlorinesource can be in a storage box or tank that stores chlorine.

In an embodiment, the chlorine source can be in a variable chlorinebatch tank or a buffer tank.

In an embodiment, chlorine can be free available chlorine which producedduring electrolysis i.e., free available chlorine. Free availablechlorine can be in the form of dissolved gas (Cl2), hypochlorous acid(HOCl), hypochlorite ion (OCl—).

In an embodiment, chlorine can be the inorganic chlorination byproductswhich are chlorate (ClO3-) and perchlorate (ClO4-). Chlorate andperchlorate are the oxidation products of active chlorine speciesproduced during electrolysis.

The term, “variable level-controlled chlorine batch tank” is defined as:a tank that holds and manages the chlorine concentrate such that aspecific chlorate level is maintained in the tank at any time as well aswhen a reasonable start up time after process interruption is less than12 hours. In an embodiment, the reasonable start up time afterinterruption is less than 10 hours, less than 8 hours, less than 6hours, less than 4, less than 2 hours, less than an hour. Aninterruption time could be 24 hours, 48 hours, 72 hours, a week or more.

The term, “volume chlorine concentrate batch tank” refers to a tank hasthe function of ensuring a sufficiently long running time of theelectrolysis unit, irrespective of the current demand, in order toprovide stable production conditions and product quality in theelectrolysis process. On the other hand, the tank provides chlorinesolution (9.0 g/ltr) at any time to ensure inline dosing for supplyingthe spray units with 100-150 ppm chlorine solution.

The term, “electrolysis” is a technique that uses electric current todrive an otherwise non-spontaneous chemical reaction. The word “lysis”means to separate or break, so in terms, electrolysis would mean“breakdown via electricity.” It may be used to produce gases viaelectrochemical reactions.

For example: the electrolysis of brine produces hydrogen and chlorinegases which bubble from the electrolyte and are collected. The initialoverall reaction is thus:

NaCl+2H2O →2NaOH+H2+Cl2

The reaction at the anode results in chlorine gas from chlorine ions:

2Cl—→Cl2+2e−

The reaction at the cathode results in hydrogen gas and hydroxide ions:

2H2O+2e−→H2+2OH—

Without a partition between the electrodes, the OH— ions produced at thecathode are free to diffuse throughout the electrolyte to the anode. Asthe electrolyte becomes more basic due to the production of OH—, lessCl2 emerges from the solution as it begins to react with the hydroxideproducing hypochlorite at the anode:

Cl2+2NaOH →NaCl+NaClO+H2O

The more opportunity the Cl2 has to interact with NaOH in the solution,the less Cl2 emerges at the surface of the solution and the faster theproduction of hypochlorite progresses. This depends on factors such assolution temperature, the amount of time the Cl2 molecule is in contactwith the solution, and concentration of NaOH.

Likewise, as hypochlorite increases in concentration, chlorates areproduced from them:

NaClO→NaClO3+2NaCl

Other reactions occur, such as the self-ionization of water and thedecomposition of hypochlorite at the cathode, the rate of the latterdepends on factors such as diffusion and the surface area of the cathodein contact with the electrolyte. In an embodiment, electrolysis of waterwill result in hydrogen and oxygen gas production.

The term, “electrolysis unit” or “electrolytic cell” or “electrochemicalcell” or “electrolytic system” or similar are defined as a unit whereinelectrolysis is carried out. An electrolysis cell has three components:an electrolyte and two electrodes (a cathode and an anode). In anembodiment, an electrolysis unit may have additional components such asbut not limited to separators. The electrochemical unit provides asource of alkalinity or acidity in addition to an oxidizing agent.Different electrolyzers function in different ways, mainly due to thedifferent type of electrolytic materials involved with them.

In an embodiment, an electrolytic system could be used for generation ofoxidizing agents/products. In an embodiment, oxidizing products obtainedfrom the electrolytic process provide a source of chlorine-basedspecies. The oxidizing agents have numerous cleanings, sanitizing and/orantimicrobial capabilities. For example, the oxidizing agents arebiocidal agents effective in killing bacteria, viruses, parasites,protozoa, molds, spores and other pathogens and are suitable for useaccording to the invention in a variety of washing systems.

The term, “in-situ” refers to, and translates literally to, “on site” or“in position”. It can mean “locally”, “on site”, “on the premises”, or“in place” to describe where an event takes place. For example: inchemistry, in-situ may mean “in the reaction mixture.” Biocidal activesubstances are called in-situ generated active substances if they aregenerated from one or more precursors at the place of use.

The term “in-situ generated active chlorine” refers to production ofchlorine by electrolysis of a chloride solution in the electrolysisunit, e.g., chlorine generated from sodium chloride or potassiumchloride by electrolysis. Chlorine manufactured by the electrolysis of asodium chloride solution (brine) or potassium chloride is known as theChloralkali process. The Chlorine produced is highly reactive. Chlorate(ClO3-) and perchlorate (ClO4-) are important inorganic chlorinationbyproducts (CBPs). Chlorate and perchlorate are the oxidation productsof active chlorine species produced during electrolysis. Chlorate andperchlorate were reported as products of mediated electro-oxidation thatinteract with, and degrade, contaminants.

In an embodiment, a concentration of perchlorate is not more than halfof a concentration of chlorate in the product of mediatedelectro-oxidation. In an embodiment, concentration of perchlorate isless than 50%, less than 45%, less than 40%, less than 30%, less than25% less than 20% concentration of the chlorate level in the product ofmediated electro-oxidation reaction.

In an embodiment, concentration of perchlorate is less than 0.1 mg/L,less than 0.05 mg/L, less than 0.02 mg/L, 0.01 mg/L, less than 0.009mg/L, less than 0.007 mg/L, less than 0.005 mg/L, less than 0.003 mg/L,less than 0.001 mg/L than in the in-use fluid.

In an embodiment, the generated chlorine is used locally at the site ofits production.

The term, “concentrate” refers to a quantity of substance present in aunit amount of a mixture.

The term, “fluid” is defined as a substance, as a liquid or gas, that iscapable of flowing and that changes its shape at a steady rate whenacted upon by a force tending to change its shape. “In use fluid” is thefluid store in the fluid distribution system and containing freeavailable chlorine. In use fluid flows inside the cabinet from the fluiddistribution system.

The term, “cabinet” refers to a space or a room designed to insert anarticle for sanitization process and to remove the article aftercompletion of the sanitization process.

The term “Free available chlorine” or “FAC” is the amount of chlorineavailable in water. This chlorine may be in the form of dissolved gas(Cl2), hypochlorous acid (HOCl), or hypochlorite ion (OCl—) or othersimilar species of chlorine but does not include chlorine combined withan amine (ammonia or nitrogen) or another organic compound.

In an embodiment, concentration of FAC is more than 1 g/L, more than 1.5g/L, more than 2 g/L, more than 2.5 g/L, more than 3 g/L, more than 3.5g/L, more than 4 g/L, more than 4.5 g/L, more than 5 g/L, more than morethan 5.5 g/L, more than 6 g/L more than 6.5 g/L, more than 7 g/L, morethan 8 g/L, more than 9 g/L, more than 10 g/L or more in the in-usefluid.

The term, “fluid distribution system” is a term for distribution ofdesired fluid using a network of pipes. A network of pipes may have aloop structure to supply fluid from a place of the generation or storageof the desired fluid to the required area.

The term, “in-use fluid” is defined as a fluid containing FAC indistribution for sterilization of articles.

The term, “microbial contaminant” refers to presence of harmfulchemicals and microorganisms which can cause illness to a consumer ofthat product. It includes pathogenic bacteria, viruses, or parasites, aswell as prions (the agents of mad cow disease), and toxins.

The term “Disinfect” is a process that either removes or reduces ordeactivates all forms of life (in particular referring to microorganismssuch as fungi, bacteria, spores, unicellular, eukaryotic organisms suchas plasmodium, etc.). Disinfection can be achieved through variousmeans, including heat, chemicals, irradiation, high pressure, andfiltration. In an embodiment, disinfection is achieved by a chemicalmeans. Throughout the specification, different terms such asdisinfection, sterilization and sanitization are interchangeably usedand mean same as per this invention.

The term, “sanitization” means that as per European Regulation, anarticle that underwent a cleaning and disinfection process according toan embodiment of the present disclosed invention and is fit for humanconsumption.

The term, “clean” refers to an act to remove dirt, contamination, andimpurities from the article. Therefore, an act of performing or aidingin soil removal, bleaching, microbial population reduction, orcombinations thereof comes under the act of clean. Cleaning is differentfrom disinfection in a way, because in cleaning majorly dirt, oil orsimilar are removed from the article. Cleaning does not kill themicrobes though some microbes may be removed unintentionally in theprocess. Disinfection is a process where intentionally microbial countis reduced to an acceptable range for a human use.

In an embodiment, cleaning step may be followed by sanitization step. Inan embodiment, cleaning and sanitization may be combined in a singlestep.

The term “Exposure time” is defined as a time span for which theoperator or the article is exposed to some chemicals.

In an embodiment, the exposure time for an operator is less than aminute. As per present invention, an article is exposed to in-use fluid.In an embodiment, exposure time is less than 60 secs, less than 50 secs,less than 40 secs, less than 30 secs, less than 20 secs, less than 10secs.

The term “pH modifier” are excipients used to adjust pH of a solution.

In an embodiment, pH modifier could be, but not limited to, soda ash,sodium hydroxide, sodium silicate, sodium phosphates, lime, sulfuricacid, and hydrofluoric acid, or similar. The addition of a base or anacid, rather than buffers, is generally recommended for pH adjustment.

In an embodiment, the present invention does not employ use of pHmodifiers.

The term “fluid spray nozzle” is a device that facilitates dispersion offluid into a form of spray. Nozzles are used for three purposes: todistribute a liquid over an area, to increase liquid surface area, andto create impact force on a solid surface.

The term, “dietary exposure” is determination of the chemical residueson a particular food or foods based on consumption data for thespecified food or foods. In the most simplified form, a dietary exposureis defined as food consumption multiplied with food chemicalconcentration. The purpose of calculating dietary exposure to a givenchemical or contaminant is so the estimated dietary exposure can becompared to a relevant health standard such as the acceptable dailyintake (ADI), the acute reference dose (ARfD) or reference dose (RfD),or a level known to cause adverse effects in animal or human healthstudies. From this comparison, one can begin to assess the risk ofadverse effects from a chemical or contaminant due to dietary exposure.

In an embodiment, spray nozzles can be categorized based on the energyinput used to cause atomization and the breakup of the fluid into drops.Spray nozzles can have one or more outlets. A multiple outlet nozzle isknown as a compound nozzle. Multiple outlets on nozzles are present onspray balls, which have been used in the brewing industry for many yearsfor cleaning casks and kegs. Spray nozzles range from heavy dutyindustrial uses to light duty spray cans or spray bottles.

In an embodiment, spray nozzles are installed e.g., in the slaughterline at the workplaces.

The term “rotating brush” is used in conjunction with a machine thatspin it on a cylinder or on a ring. This spinning motion cleans hardsurfaces to be treated or articles that meet the brush's bristles.Further these rotating brushes provide a more mechanical way of cleaningaction on the article. Rotating brushes can be manufactured in a varietyof configurations, and they are usually made to be replaceable once thebristles wear out from too much use.

The term, sprayer is a device used to spray a liquid. Sprayers areusually integrated mechanical systems, that means they are composed ofvarious parts and components that work together to achieve the desiredeffect, in this case, the projection of the spray of a fluid. This canbe as simple as a hand sprayer attached to a bottle that is pumped andprimed by a spring-lever, a tube, and vacuum-pressure; or as complex asa 150-foot reach boom sprayer with a list of system components that worktogether to deliver the spray fluid. For complex sprayers, common systemcomponents include: the spray nozzle, sometimes with a spray gun, fluidtank, sprayer pump, pressure regulators, valves and gaskets, and fluidplumbing. The sprayer pump can be just as important as the sprayer typeitself as there are many sprayer pump design types with variousconstruction materials, inlet/outlet sizes, and performancespecifications. Common sprayer pump types include diaphragm,centrifugal, and roller pumps. Examples of general sprayer typesinclude, but not limited to, a boom sprayer, Boomless sprayer nozzle,mist sprayer, three-point hitch sprayer, truck-bed sprayer, towing-hitchsprayer, utility task vehicle UTV sprayer, all-terrain vehicle ATVsprayer, spot sprayer, back-pack sprayer, or similar.

The term, “diluting unit” is the unit designed for diluting the solutionto a predetermined concentration. For example, the diluting unit couldbe a source of water that can be used with the methods, systems, andapparatus of the present invention. Exemplary water sources suitable foruse in the present invention include, but are not limited to, water froma municipal water source, drinking water, or private water system, andthe like.

The term “feed electrolyte” is defined as a chemical that is introducedin the electrolytic cell to undergo electrolysis to produce the chlorineor desired chlorine species.

The term “a hot water basin system” is an appliance that holds a hotwater. In a hot water basin, temperature of the water is between 80° C.to about 100° C.

The term “multi-knife technology” involves at least two knives. Duringthe slaughtering process, instruments used in between the processing ofthe various carcasses must be disinfected. The first knife is sanitizedin a hot water basin, while the second knife is used to cut. After that,the knife is replaced with a new knife for the second cut, and the usedknife is sanitized in a hot water bath. For each cut, the procedure isrepeated. In slaughterhouses in particular, it must be ensured that themeans of treating slaughtering tools, such as knives, are constantly andreliably cleaned and decontaminated during the slaughtering process inorder to avoid the transmission of pathogens from one carcass toanother. For this purpose, the so-called multi-knife technology is usedin the slaughterhouse: In this technology, the butcher opens a firstanimal with a first knife, which he then puts in a hot water basin. Witha second knife, a second animal is opened, and then the second knife isput in the same hot water bath. A third animal is then opened with thefirst knife. Through the water bath, germs are to be killed andpollutions are diminished and so a transfer of germs from one animal tothe next animal is to be prevented.

In an embodiment, multi-knife technology is also called as two-knifetechnology.

The term, “single knife technology” refers wherein same knife could beused for processing of the various carcasses and simultaneously beingdisinfected. Unlike multi-knife technology, there is no two kniveswherein the first knife is sanitized in a hot water basin, while thesecond knife is used to cut. The process of processing carcass anddisinfection of carcass is done simultaneously within span of secondsusing same knife.

The term “article” is an object. In an embodiment, the article comprisesa knife. The article may include knives, woven and non-woven fabrics,textiles, sinks, instruments, saws, axes, round knives, and the like.

The term “butchery” is the trade or business of a butcher wherein abutcher takes a section of meat and break them into small portions orcustom cuts which can be sold to customers. The act of butchery is donein slaughterhouses.

The term “horticulture” is defined as the science and art of thedevelopment, sustainable production, of high-value, intensivelycultivated food and ornamental plants.

The term “colony-forming unit (CFU or cfu)” is a measure of viablebacterial cells. In direct microscopic counts (cell counting usinghaemocytometer) where all cells, dead and living, are counted, but CFUmeasures only viable cells.

Counting with colony-forming units requires culturing the microbes andcounts only viable cells, in contrast with microscopic examination whichcounts all cells, living or dead. The visual appearance of a colony in acell culture requires significant growth, and when counting colonies itis uncertain if the colony arose from one cell or a group of cells.Expressing results as colony-forming units reflects this uncertainty.

The purpose of plate counting is to estimate the number of cells presentbased on their ability to give rise to colonies under specificconditions of nutrient medium, temperature, and time. Theoretically, oneviable cell can give rise to a colony through replication. However,solitary cells are the exception in nature, and most likely theprogenitor of the colony was a mass of cells deposited together. Inaddition, many bacteria grow in chains (e.g. Streptococcus) or clumps(e.g., Staphylococcus). Estimation of microbial numbers by CFU will, inmost cases, undercount the number of living cells present in a samplefor these reasons. This is because the counting of CFU assumes thatevery colony is separate and founded by a single viable microbial cell.

The term, “CFU/cm2” is the number of colonies formed per cm2 of surface

There are numerous influences on physical, chemical, biocidal and riskrelated properties of the active chlorine used for biocidal purposes: pHvalue, excess salinity, buffer capacity of the de-hardened water usedfor preparing the electrolyte.

Of these properties, the pH of the biocide solution is decisive bothwith concerns regarding operators' exposure towards hypochlorous acid(at a lower pH of <7.4) and for biocidal efficacy against targetorganisms, which is negatively affected by higher pH values (HOCl andCl2, are the more reactive species, despite having the same Cl+1oxidation state as the hypochlorite ion). Both operator safety andpotential consumer exposure towards chlorate are pre-conditions thatcannot be negotiated; however, microbiological efficacy is also anabsolute prerequisite for e.g. successful registration and actual use incritical food-contact applications.

Table 1 gives an idea how pH and buffer capacity (determine theprevalence of a certain, initial pH) of electrolyzed chlorine solutionsand the impact from unavoidable byproducts present are related tooperators' exposure and safety, as well as to the legal requirements (orexpectations) in terms of microorganism control.

TABLE 1 pH and buffer capacity of electrolyzed chlorine solutions andthe impact of unavoidable byproducts on operators' exposure and safetyClO₃ formation upon storage, relative to Antimicrobial efficacy chlorinepresent Operator's risk pH-value +pH (More than 7.4 pH), +pH, more ClO₃,+pH, less risk, no less efficacy, higher decomposition process vaporfrom concentration so longer shifted from oxygen hypochlorous acid,contact time needed. release to only aerosol exposure disproportionationat towards an aqueous higher pH solution of a non- volatile ion. Bufferhigh buffer capacity/ capacity carbonate hardness negative, delays pHdrop upon decomposition.

A person skilled in the art would either lower the concentration and/orincrease disinfectant temperature to overcome the shortcomings of thedevices used in the state of the art. Further, in order to minimizeoperator exposure, a normal optimization procedure would start atlowering the in-use concentration of active chlorine, whilesimultaneously having to accept longer treatment times (which is highlyunwanted in industrial food processing operations) and/or increasetemperature in order to improve antimicrobial action of the activesubstance. While the reduction of concentration may be a beneficialimpact on operators' exposure, the increase of temperature will lead toboth increased operators' exposure due to a higher hypochlorous acidvapor pressure at elevated temperatures and increased problems withmaterial compatibility of hot, aqueous chlorine solutions containing anexcess of the precursor (alkali chlorides).

Alternatively, one might consider using treatment devices that have alower formation rate of aerosol or vapor, compared to the highlyefficient 2-phase spray nozzles used in present invention. Theseconsiderations further lead away from the disclosed state-of-the-artsystem, ending at the most common use of a hot water/disinfectantbath—where the tools to be disinfected are simply inserted/soaked, nothaving the beneficial effect of mechanical action in a two-phasespraying environment, and also risking re-contamination with collectedsoil removed from treated surfaces, that subsequently is in contact withall devices treated in the same bath.

In an embodiment of present invention, a reasonable start up time afterprocess interruption is less than 12 hours. Process interruption couldbe scheduled process interruptions of up to 72 hours (for example overweekends). In an embodiment, the reasonable start up time afterinterruption is less than 10 hours, less than 8 hours, less than 6hours, less than 4, less than 2 hours, less than an hour. Aninterruption time could be 24 hours, 48 hours, 72 hours, a week or more.

In an embodiment of the present invention, decomposition of in-situgenerated chlorine solution is less than 50%, less than 40%, less than30%, less than 25%, less than 20%, less than 10% of the availablechlorine over a period of several days.

In an embodiment, there is no increase in chlorate content after storagetime of 6 months, 1 year, 1.5 years. In an embodiment, increase inchlorate content is not more than 10%, 15%, 20%, 30%, 35%, 40% of theconcentration that was present just before the storage time.

In an embodiment, storage time is 1 month, 3 months, 6 months, 1 year,1.5 years or 2 years or more.

In an embodiment of present invention, perchlorate concentrations do notexceed half of chlorate concentration in the solution. In an embodiment,perchlorate concentration is less than 40%, less than 30%, less than25%, less than 20% of the chlorate concentration in the solution.

In an embodiment, concentration of perchlorate is below the limit ofdetection (LOD) of the most recent High Performance Ion Chromatographysystems.

In an embodiment, perchlorate is about 0.01 mg/L, less than 0.01 mg/L,less than 0.0075 mg/L, less than 0.005 mg/L or less than this in thetotal solution.

It is also important to consider that results of the novel disinfectionprocess do match or exceed the results achieved by the standard 82° C.hot water bath treatment, currently established in e.g. most industrialmeat processing plants.

In an embodiment of the present invention, disinfection of an articleleads to decrease in microbial count less than 7 CFU/cm², 6 CFU/cm², 5CFU/cm², 4 CFU/cm², 3 CFU/cm², 2 CFU/cm², 1 CFU/cm².

In an embodiment, disinfection with in-situ generated active chlorine ata pH, at site of use, of more than 7.4. The in-use solution may bediluted prior to being used.

In an embodiment, disinfection with in-situ generated active chlorine isachieved at a pH of more than 7.4. A pH of more than 7.4 is attained byusing a diluted hypochlorite ion concentration of more than 50 Mol %hypochlorite ion. This is achieved without modifying the pH of the feedelectrolyte/chlorine concentrated/diluted in-use solution in any way. Onthe contrary, in the prior art, disinfection was achieved either bylowering the pH to improve antimicrobial efficacy or lowering theinitial and post storage specific chlorate concentrations.

In an embodiment, in-situ generated active chlorine is more than 50 Mol% of the hypochlorite ion. In an embodiment, in-situ generated activechlorine is more than 60 Mol %, more than 65 Mol %, more than 70 Mol %,more than 75 Mol %, more than 80 Mol %, more than 85 Mol % of thehypochlorite ion.

In an embodiment, this is achieved without pH-relevant modifications tothe feed electrolyte/chlorine concentrated/diluted in-use solution.

This achievement is not obvious to a person skilled in the art becauseone would rather use a lower pH to a) improve antimicrobial efficacy,and (b) typically have lower initial (and post-storage—short term) forspecific chlorate concentrations. Further, this only could be achievedwith split-cell, low chlorate electrolysis devices.

In an embodiment, a standard open cell electrolysis device, which isusually used in swimming pool, Potable water, Process water or otherapplications, is employed in the system where the systemic/dietaryexposure of consumers towards impurities such as chlorate is highlyunlikely. On the contrary, in the prior art, the effect of a lower pH inthe electrolyte and a much lower initial specific chlorate content isfar less important than measures taken to maintain a compliant chloratelevel in the batch tank (always feeding the dilution unit)—even afterrestart following a scheduled process interruption.

In an embodiment, a variable/dynamic level-controlled chlorine batchtank is used to guarantee both compliant specific chlorate levels aswell as reasonable startup times after process interruptions. This isalso not obvious, because there will be a certain start-up time requiredto operate under safe dietary conditions after a longer processinterruption (e.g. >12 hours, compared to a single-level operatedtank—always full). Implementation of a controlled, variable level tankis a technical feature one would try to avoid.

In an embodiment, the system comprises a mandatory two-step process,i.e., a cleaning step and a disinfecting step using disinfectingsolution. This two-step process ensures that antimicrobial action takesplace on an as-clean-as-possible surface and thereby allowing to assessantimicrobial efficacy under so-called (EN antimicrobial efficacytesting standards) “clean conditions”, using less, or less impactful,soiling substances in the standard efficacy essays.

In an embodiment, the system comprises no pre rinse or post rinse stepwith different kinds of liquid medium in cleaning an article.

In an embodiment, the system comprises two-fluid spraying nozzleswherein the pressure is low to medium. Two-fluid spraying nozzle placedin a cabinet, wherein two-fluid spraying nozzle will provide the mostintense contact between the disinfection solution and the hard surfaceto be treated, resulting in shorter treatment times and lower operatorexposure.

In an embodiment, system comprises low to medium pressure 2-fluidspraying nozzles. Two-fluid spraying nozzle, placed in a suitablecabinet, will give the most intense contact between disinfectantsolution and the hard surface to be treated, resulting in low treatmenttimes and relatively moderate operators' exposure.

In an embodiment, the system further comprises revolving brushes to addmore mechanical activity in the system.

In an embodiment, the system comprises rotating brushes for obtainingmore mechanical action, but the problem is that rotating brushes may endup in severe microbiological problems on the surfaces of the brushingdevice and is not a viable option to further increase mechanical action.

In an embodiment, the temperature of in use fluid in the system islightly elevated up to 45° C. The temperature of the in-use fluid isabout 35° C., 40° C., 45° C., 50° C., 55° C., 60° C., 65° C.

In an embodiment, system allows short contact times such as less than 2mins, less than 60 secs, less than 45 secs, less than 30 secs, less than25 secs. Increasing aerosol formation, and vapor formation may not besignificant as pH is more than 7.4.

In an embodiment, there is no presence of hypochlorous acid. In anembodiment, presence of hypochlorous acid is less than 1%, less than0.5% concentration in the solution.

An embodiment relates to present in-situ chlorine processes.

An embodiment relates to a disinfection process that is applicable forall types of meat, for example, but not limited to, pork, beef, poultry.

Advantages of the present invention over state of art.

A mandatory 2-step disinfecting/cleaning step with disinfectant solution(no post- or pre-rinse/clean with different kind of liquid medium): Thistwo-step process ensures that antimicrobial action takes place on anas-clean-as-possible surface and thereby allowing to assessantimicrobial efficacy under so-called (EN antimicrobial efficacytesting standards) “clean conditions”, using less, or less impactful,soiling substances in the standard efficacy essays.

Low to medium pressure 2-fluid spraying nozzles: Two-fluid sprayingnozzle, placed in a suitable cabinet, will give the most intense contactbetween disinfectant solution and the hard surface to be treated,resulting in low treatment times and relatively moderate operatorsexposure. Obtaining even more mechanical action by introducing e.g. arotating brush, will end up in severe microbiological problems on thesurfaces of the brushing device and is therefore not a viable option tofurther increase mechanical action.

A slightly elevated temperature up to 45 degrees: Shortening requiredcontact times, not significantly increasing aerosol formation, and:Vapor does not have to be considered since pH >7.5 (no hypochlorous acidpresent).

In an embodiment, the disinfection process is applicable in all types ofcutting processes. In an embodiment, the system could be used for allcutting tools, organ shells, hook hygiene, etc. Applicable in all typesof cattle lines and modular concepts for any size of system web-basedhygiene platform.

In an embodiment, the disinfection process is manual, automated, or acombination of manual and automation process.

In an embodiment, the disinfection process results in a lower microbialcount on the article as compared to the 82° C. hot water system.

In an embodiment, the process involves a cleaning step.

In an embodiment, the process does not involve a rinsing step due to theresidue profile.

In an embodiment, in using the electrolytic system, there is less amountof water consumed in the process, lower energy costs, and simplerimproved work routines, and/or minimal changes, etc.

In an embodiment, the electrolytic system uses little floor space at theworkplace and provides improved work safety.

In an embodiment, the sanitation process is a two-stage process with acleaning stage and a disinfecting stage.

In an embodiment, the electrolytic system does not require a waterbasin. Therefore, there is no dirt accumulation.

In an embodiment, temperature of disinfection solution is around 40° C.In an embodiment, minimum temperature of the disinfection solution couldbe 30° C., 35° C., 40° C., 45° C., 50° C., and the maximum temperatureof the solution could be 40° C., 45° C., 50° C., 55° C., ° C., 70° C. ormore.

In an embodiment, the active substance is in-situ chlorine.

In an embodiment, the system has a biocidal effectiveness such asbactericidal and yeasticidal efficiency. It has a cleaning effect.

In an embodiment, the system uses two fluid technology for water savingand strong cleaning effect. In an embodiment, the system is easy toinstall and operate. We can use the same pipe system (if possible)and/or Air supply (both must be planned individually). In an embodiment,the system requires installation of a generator.

In an embodiment, the system provides an incomparable cleaning effect tothe article, such as, but not limited to, a tool. The tool could be aknife, saw, axe, round knife used in automated poultry lines, and alltypes of automated cutting. In an embodiment, the system is used forsanitization of robots in the slaughter line and all types of automatedcutting.

In an embodiment, the knife tip stands up vertically down in the chamberso there is no backflow of dirty water. The cut protection glove on theleft hand can also be cleaned. The fluid has a mild temperaturetolerable to human skin.

In an embodiment, the system has automated knife and hook washingstations.

In an embodiment, this system is not a multi-knife technology.

In an embodiment, the knife keeps the sharpness because there is nodeposit of protein and lime on the knife.

In an embodiment, we are working at much lower temperatures compared tothe hot water basin system at 82° C. It is impossible to hold the handinto the hot water basin without burning it. In the present invention,the fluid sprayed is around 40° C. which is below the melting point ofthe fat, for example pork fat or chicken or turkey fat, which isimportant in that the knife doesn't get slippery, which is the problemin the prior art where they use hot water in the rinsing bath.

In an embodiment, 35° C. to 40° C. water temperature, used in thepresent invention, is acceptable to an operator's hand.

In an embodiment, we compared the classical hot water basin system withthe present invention to evaluate the resulting CFU/cm² remaining afterdisinfecting the article. The present invention had much lower CFU/cm²,contaminates, on the article.

In an embodiment, the present invention saves a lot of water and energycosts, because to keep the water in a cold environment at 82° C. costs alot of energy. And we have to replace water very rapidly in order toavoid buildup of extreme dirt in the basins.

In an embodiment, the system uses in-situ chlorine. In-situ chlorine hasan advantage over using processed and delivered chlorine bleach; becausesuch processed chlorine, when delivered and stored, develops more andmore harmful species which are very bad for dietary risk assessment.

In an embodiment, in-situ chlorine reduces certain chlorine species.

In an embodiment, there is no water basin. Therefore, there is noaccumulation of dirt in this electrolytic process.

In an embodiment, we are using a two-step system, that is a cleaning anda disinfection step. According to biocidal product regulation, cleaningis not enough using simple water. There has to be a cleaner ordisinfection solution.

In an embodiment, in the system, time to expose an article to the fluidfor sanitization is less than a minute. In an embodiment, time ofexposure could be about 0.5 seconds, 1 second, 2 seconds, 3 seconds, 4seconds, 5 seconds, 10 seconds, 20 seconds, 30 seconds, 45 seconds. Inan embodiment, the article is exposed to the cleaning step and/ordisinfecting step for less than a minute respectively. In an embodiment,the article is exposed to the cleaning step for about 1 second, 2seconds, 3 seconds, 4 seconds, 5 seconds, 10 seconds, 20 seconds, 0.5mins, 1 min, 2 mins, 3 mins, 4 mins, 5 mins. In an embodiment, thearticle is exposed to the disinfecting step for about 0.5 mins, 1 min, 2mins, 3 mins, 4 mins, 5 mins.

In an embodiment, the system uses a disinfection solution for cleaning,it is convenient to run the cabinet, as we have, to install one pipe forthe disinfecting solution, not two pipes for water and disinfectingsolution, and so on.

In an embodiment, dirt is drained out using a few milliliters ml of thedisinfection solution.

In an embodiment, the system is using two fluid technology. There ismixing of water and air to have a better mechanical effect and lowerwater demand, and this also allows the mechanical effect to obtain abetter cleaning effect.

In an embodiment, the active substance is in-situ chlorine in theconcentration of about 9.0 grams/liter.

In an embodiment, the disinfection solution contains an active substancein the range of about 100 ppm to 150 ppm. In an embodiment, thedisinfection solution contains an active substance in a range of about120 ppm to 170 ppm, 120 ppm to 160 ppm, 130 ppm to 150 ppm. In anembodiment, the minimum concentration of the active substance in thesolution is 25 ppm, 30 ppm, 40 ppm, 50 ppm, 60 ppm, 70 ppm, 80 ppm, 90ppm, 100 ppm; and the maximum concentration of the active substance inthe solution is about 120 ppm, 130 ppm, 140 ppm, 150 ppm, 160 ppm, 170ppm, 180 ppm, 190 ppm, 200 ppm.

In an embodiment, temperature of the solution is around 40° C.

In an embodiment, one step of cleaning is not allowed as per EuropeBiocidal Regulation.

In an embodiment, inside the cabinet at the level of the hand there is apressure plate and on the side several nozzles that produce the in-situand effective concentration of the product diluted with the water.

In an embodiment, effectiveness of the intervention was tested in afield study by the Goldschmaus Group under real conditions for a totalof 5 seconds for the cleaning and disinfection step in comparison to the82° C. method.

In an embodiment, after application the new method showed results in therange of 1-2 CFU/cm² (FIG. 2 ) on average on the cutting tool, whereasthe 82° C. method showed results in the range of about 2-4 CFU/cm² (FIG.3 ). In the 82° C. method, the remaining microorganisms on the tool aresignificantly higher compared to the new method of this invention. Theseresults could be reproduced in other cattle lines. Therefore, the newmethod disinfects the tool better than the 82° C. method. In anembodiment, the CFU/cm² average on the cutting tool is less than 4, lessthan 3, less than 2, less than 1 or no CFU.

In an embodiment, the system disinfected the article with CFU/cm² countless than 2, less than 1. In an embodiment, the system completelydisinfected the article with no colonies observed per cm².

In an embodiment, the field tests showed a high level of user acceptanceof the electrolytic process, which can significantly improveslaughterhouse hygiene. Standardization of the entire electrolyticprocess, including the creation of automated records, is also possible.

In an embodiment, the in-situ chlorine technology presented here withoutrinsing requires proof of toxicological harmlessness of the remainingresidues of the application solution on the cutting tool surfaces.

In an embodiment, for this purpose the remaining water volumes and thetoxicologically relevant chlorine species were quantified and assessedin a so-called Dietary Risk Assessment (DRA) for adults and smallchildren.

In an embodiment, cleaning and disinfecting with a solution.

In an embodiment, present invention has better economics, due to waterand energy savings.

In an embodiment, present invention disinfects knife and guiding hand.

In an embodiment, present invention is suitable for cattle and ingeneral high temperature melting fat.

In an embodiment, present invention produces no odor irritation athigher temperature

In an embodiment, present invention fulfils the high standard hygienedemands of EU law for slaughtering hygiene

In an embodiment, the new requirements of the International FoodStandards IFS version 7 are implemented in a well-versed manner.

Regulatory Requirements with Regard to Impurity Residues in Food (EU)

According to standard Deutsches Institut fur Normung (DIN) 901<5.4% MaxNaClO₃ of FAC. (DIN (Deutsches Institut fur Normung) 901 is the German“Chlorine for use in water treatment” standard, quoted in BiocidalProduct Regulation Approval Decision for the active substance generatedin-situ.)

Endpoints considered: ADI (allowable daily intake) chlorate (as NaClO₃):0.003 mg/kg BW·day (equal to 0.0024 mg/kg BW·day as ClO₃ ⁻), Arfd (acutereference dose) chlorate (as NaClO₃): 0.003 mg/kg BW·day (equal to0.0024 mg/kg BW·day as ClO₃ ⁻) (Source: EFSA), Maximum residue level(MRL) for chlorate; the smallest MRL from Commission Regulation (EU)2020/749 has been used as a worst-case (0.05 mg/kg BW·day of chronicexposure towards chlorate).

Perchlorate is considered to be a non-threshold thyroid endocrinedisruptor.

Compliance shall be confirmed by modelling dietary exposure forconsumers (including toddlers) and comparison of (also combined)exposure with chlorate AEL.

The use of the available EFSA/ECHA Guidance and bespoke models isrequired for assessment of dietary exposure.

Non-compliance would lead to a non-authorization decision and subsequentloss in marketability. Similar regulatory regimes exist e.g., in theUnited States of America.

Perchlorate concentrations shall at least not exceed e.g., half ofchlorate, ideally being below the LOD of the most recent HighPerformance Ion Chromatography systems (e.g., 0.01 mg/L CLO⁴⁻).

It is also important to consider that results of the novel disinfectionprocess do match or exceed the results achieved by the standard 82° C.hot water bath treatment, currently established in most industrial meatprocessing plants.

There are also massive concerns in some parts of the world, for examplein the European Union, regarding chlorine in contact with food.

While a standard procedure in the United States, it is not allowed totreat/disinfect food with chlorine (FAC) solutions in Europe. This wouldlead to the requirement of a post rinse with drinking water, in casehigh chlorine concentrations are used to disinfect tools that come intocontact with food.

It is therefore required to compare the maximum amount of chlorinetransferred to e.g., a full carcass rinsed off with drinking water atthe given maximum permitted drinking water chlorine concentration (acommon and allowed practice), with the amount of chlorine transferred toa comparable piece of food (comparable in terms of surface to massratio) by the disinfected (and not rinsed) cutting tool.

WORKING EXAMPLE Example 1: Slaughtering, Meat Processing

Investigation was done to study the advantages of the procedure comparedto existing implementations serving the same purpose during its actualuse with all types of meat.

The in-use temperature of up to 45° C., which is close to the meltingpoint of a vertebrate fat, offers an excellent result for both fatresidue cleaning and protein and blood residue cleaning, as these do notdenature at this low temperature.

An optically free result, which means shiny bright stainless blades areobtained in fraction of seconds which is due to mechanical action of thetwo-substance nozzle with minimum water consumption and the arrangementin the cabinet. This surface condition is considered to be the optimumprerequisite for the subsequent disinfection step.

Limestone deposits on the blade, which are frequent in sterilizing tanks(where high temperatures reduce carbon dioxide solubility), do not existat 45° C. This significantly extends the time between bladeresharpening, which is a definite advantage.

In an embodiment, the saws, the nozzle arrangement and media supply areintegrated into the unit. The regular cleaning intervals and mechanicalassistance of the two-fluid nozzles remove not only the aforementionedfat and protein, but also tendon residues and bone meal, ensuringoptimal preparation for the upcoming disinfection stage.

In an embodiment, operator will not notice any chlorine odour due to thehigh pH value of 7.5-8.5, and the low in-use concentration of 100-150ppm FAC.

In an embodiment, system is equipped with a buffer tank for theconcentrate (e.g. 9 g/L of FAC), from which the in-use solution for thesupply of the cabinets and other points of use is produced by an inlinedosing/dilution system. Un-treated tap-water is used for dilution.

In an embodiment, buffer tank also allows the electrolysis cell to runfor a longer period of time in the optimal operating range with thelowest achievable oxidised chlorine by-products level (achievable withthe electrolysis device chosen).

This is an elementary prerequisite for safely falling below thetoxicological limits in the dietary risk assessment (DRA).

The measured surface microbial counts on various selective media show inmost cases no findings.

Example 2: Packaging Cheese Slicer Department

Before packaging, many types of food are cut into portion-sized slicesor pieces. For this purpose, slicers are used which are an integral partof the packaging line in order to keep the risk of contamination as lowas possible during this hygienically sensitive process step. Thisprocess step takes place at very cool ambient temperatures. The cheeseor similar kind of product is usually frozen or at least cooled stronglyin order to have optimal mechanical properties during cutting. Due tothe high hygiene requirements, the slicer and the packaging line have tobe subject to periodical, intermediate disinfection.

For this purpose, cleaning and disinfection is carried out with thein-situ chlorine solution at a temperature of up to 45° C. The solutioncools down on the cold cutting surface. The solution cools down veryquickly on the cold machine parts, but the higher temperature ensures avery good initial cleaning and disinfection effect. The residual wateris blown off with compressed air, so that after the process a drysurface is again available for the continuation of the packagingprocess.

Compared to the previously practiced method with highly concentratedalcohol solutions, the advantage is that the employees are not exposedto alcohol vapours, inducing drowsiness and associated risk fordangerous incidents. Furthermore, there is no danger of explosion fromhigh airborne alcohol concentrations—no VOCs are emitted.

Example 3: Horticulture

In plant cultivation, both flowers and vegetables (tomatoes, peppers,etc.) are grown in large greenhouses with close stocking. In order toavoid microbial infections caused by bacteria, yeasts and moulds inthese cultures, the plants must be constantly maintained by removingdeceased plant parts. The scissors, knives and cutting tools musttherefore be cleaned and disinfected in the cabinet using thetwo-substance nozzle method in order to avoid cross-contamination amongthe plants.

Dietary considerations have to be made (chlorate levels transferred bythe cutting tool blades), be it for edible parts removed/harvested, orfor withdrawn parts of the plants that end up in the (on-site)fertilizer cycle (compost treatment of biological waste).

Example 4: Human Health Assessment—Operator's Exposure Towards AirborneChlorine

When used according to one of the most envisaged use-areas (disinfectionof cutting tools in industrial meat processing), the differences betweenthe state-of-the-art (with low-chlorate and low-pH solutions) andpresent invention (with the use of high-pH (>7.5) low-medium chloratehypochlorite solutions), the significance of strict pH-control—whilestill fulfilling efficacy requirements—becomes clearly visible.

Calculations of operator's exposure towards airborne FAC-species isbased on the most recent EU Guidance and legislation and exposureassumptions, both are pointed out in the table 2 below:

-   -   Scenario: Soaking/spraying of cutting tools in industrial        production—professional user, no Personal Protective Equipment        (PPE) or Respiratory Protective Equipment (RPE) acceptable    -   Model for dermal exposure: Semi-quantitative assessment    -   Model for inhalation exposure: EU Commission and Agency        Guidance: Technical notes for guidance (TNsG) spraying model 1        (Aerosol assessment) and HEAdhoc 16, 2 Compound Model I (Vapour        assessment).

TABLE 2 The calculations of operator's exposure towards airborneFAC-species based on the most recent (2022) EU Guidance and legislationand exposure assumptions. Product details Unit Present invention Stateof art Permanent exposure over 8 Permanent exposure over 8 hour shift,160 applications/ hour shift, 160 applications/ shift (every 3 mins.)shift (every 3 mins.) Release Area (Tier-1): 1 m³ Release Area (Tier-1):1 m³ Active substance Active chlorine from OCl- Active chlorine fromHOCl (pH > 7.5) (pH < 7.4) Equal to 100 mg/l in- % 0.01 0.01 useconcentration FAC (as Cl₂) Local exposure Dermal exposure Tier-1 Tier-1Concentration in in-use % 0.01 0.01 dilution [active substance] NOEACdermal % 1.0 1.0 % NOAEC dermal % 1.0 1.0 Inhalation exposure - Tier-1Tier-1 Aerosol Concentration in in-use % 0.01 0.01 dilution [activesubstance] Indicative value mg/m³ 104 104 (Module A4) Inhalationexposure mg/m³ 0.0104 [active substance] NOAEC (No Observed mg/m³ 0.50.5 Adverse Effect Concentration) inhalation % NOAEC inhalation % 2.082.1 Inhalation exposure - Tier-1 Tier-1 Vapour Indicative value mg/m³0.05466 Number of applications /day 160 Inhalation exposure mg/m³ 8.7456[active substance] NOAEC inhalation mg/m³ 0.5 % NOAEC inhalation %1749.12 Total inhalation Tier-1 Tier-1 exposure - Aerosol + vapour(below pH 7.4) Total inhalation mg/m³ 8.756 0.0104 exposure [activesubstance] NOAEC inhalation mg/m³ 0.5 0.5 % NOAEC inhalation % 1751.22.08

Calculations demonstrate that the use of high-pH hypochlorite solutionsis perfectly safe, both for dermal and inhalation exposure (aerosols),even if (realistically) permanent operator's exposure over an 8 hrsshift is assumed (total dermal+inhalation approx. 3% of NOAEC (FAC)).

If, according to the state-of-the-art, a low-chlorate FAC solution witha pH below 7.4 is used, un-dissociated hypochlorous acid is thepredominant chlorine species. Its significant vapour pressure leads to amandatory consideration of a HOCl vapour assessment—and consequently toa 17-fold exceedance of the NOAEC (1,750%).

It is clear, that even less conservative assumptions regarding actualexposure time of operators will not lead to safe conditions.

The same is true for lowering the in-use concentration somewhat (whichmight be feasible, due to better FAC efficacy at lower pH values atidentical Cl₂-concentration), the level of exceedance is simply toolarge to be compensated by realistic refinements of exposureassumptions.

Conclusion: Albeit exhibiting a potentially higher initial specificchlorate content and being less efficacious towards target organisms (ata given FAC concentration), the use of the high-pH solution according tothe invention proves to be required—in order to fulfil human healthconsiderations from EU (or US FDA, EPA) Regulators.

SUMMARY OF EXAMPLES—ADVANTAGES OF INVENTION

In an embodiment, a system/process comprising a commercially available(preferably open-cell) chlorine electrolysis device, a variable-leveloperated batch tank to hold and manage the chlorine concentrate, anin-line (tap water) dilution and liquid transport unit and a sprayingcabinet with 2-phase fluid nozzles, to drain, designed for carrying-outa 2-step, combined cleaning and disinfection process on surfaces ofcutting tools (non-rinse). These tools come into contact withfood/feeding stuff and the whole setup is configured to providecompliant antimicrobial efficacy results, while observing allowable(dietary) levels of toxicologically relevant by-products (chlorate,perchlorate) remaining on cutting tool surfaces and simultaneouslyensuring shortest treatment times—with the least level of operator'sexposure towards hypochlorous acid vapor.

In an embodiment, the process is suitable for all cutting and sawingoperations in the entire slaughter and primal cutting process, whetherperformed manually or automatically, in red and white meat.

In an embodiment, automated operations in pig or cattle slaughtering,such as splitting robots, the two-substance nozzle can be integratedinto the cleaning cabinet of the respective machine.

In an embodiment, in poultry slaughtering lines, the process isintegrated in the rotary machines—such as the vent cutter, eviscerationor neck cracker.

In an embodiment, the system may also be used in transport hygiene suchas the hook wash and the conveyor belts of the integral logistics.

In an embodiment, another field of application is the intermediatecleaning and disinfection in slicer lines for meat, vegetarian andcheese products.

In an embodiment, the system or process may also be used for the hygieneof cutting and processing equipment of fruit and vegetable products,particularly on ready-to-eat process lines.

In an embodiment, the system or process may also be used for theintermediate hygiene of tools for cutting and treating the plants in thehorticulture. To avoid cross contamination while removing ill orcontaminated parts of the plant, the tools have to be kept in a veryhigh sanitation level—while ensuring a flexible operation in largegreenhouses and an acceptable level of chlorine by-product contaminationin this (also) non-rinse application.

All references, including granted patents and patent applicationpublications, referred herein are incorporated herein by reference intheir entirety.

1. A system, comprising: (a) a reservoir of a chlorine source, (b) anelectrolysis unit, (c) a storage tank, and (d) a fluid distributionsystem, wherein the chlorine source is configured to be fed into theelectrolysis unit to generate a solution having the in-situ activechlorine comprising free available chlorine (FAC), wherein the storagetank is configured to store the solution, wherein the fluid distributionsystem is configured to distribute the solution to a point of use;wherein the solution at the point of use has: (i) a concentration ofperchlorate not more than half of a concentration of chlorate; (ii) pHabout 7.5 to about 8.5; (iii) more than 50 Mol % of hypochlorite ion asthe FAC; (iv) a concentration range of the FAC more than 1 g/L to about10 g/L; (v) less than 1 Mol % of hypochlorous acid as the FAC; whereinthe system is configured to: a) reduce a microbial contaminant from anarticle exposed to the solution at the point of use for a particulartime having temperature between about 30° C. to about 60° C., such thatthe microbial contaminant remaining after treatment is less than that ofthe microbial contaminant remaining on the article after being exposedto a hot water basin system for the same particular time and havingtemperature of the hot water basin fluid between about 80° C. to about100° C.; and b) avoid cross contamination between items cut using thearticle sterilized by the solution at the point of use.
 2. (canceled) 3.The system of claim 1, further comprises a variable level-controlledchlorine batch tank configured to store a chlorine concentrate generatedfrom the electrolysis unit such that a specific level of the chlorate inthe chlorine concentrate is maintained. 4-5. (canceled)
 6. (canceled) 7.The system of claim 1, wherein the concentration of the perchlorate isabout 0.02 to 0.001 mg/l in the solution at the point of use. 8.(canceled)
 9. The system of claim 1, wherein the particular time is lessthan 1 minute.
 10. The system of claim 36, wherein the pH of thesolution is achieved without use of a pH modifier to alter pH of a feedelectrolyte. 11-13. (canceled)
 14. The system of claim 1, wherein thetemperature of the solution at the point of use is about 30° C.-about50° C. 15-16. (canceled)
 17. The system of claim 1, wherein aconcentration of the FAC calculated as Cl₂ in the solution stored in astorage tank is about 9 g/L. 18-20. (canceled)
 21. The system of claim1, wherein the microbial contaminant on the article after being exposedto the solution for less than a minute decreases to less than 2 CFU/cm².22-25. (canceled)
 26. The system of claim 1, wherein the electrolysisunit is an open cell electrolysis unit.
 27. (canceled)
 28. The system ofclaim 1, wherein an operator exposure to inorganic chlorine speciesduring usage of the solution at the point of use in a working shift, ofabout 8 hours and 160 applications, wherein each application is about 3mins, has no observed adverse effect concentration (NOAEC) inhalation ofabout 0.5 mg/m³.
 29. (canceled) 30-33. (canceled)
 34. A fluid comprisingfree available chlorine (FAC) comprising 50 Mol % of hypochlorite ionand a concentration of perchlorate not more than half of a concentrationof chlorate in the fluid, wherein pH of the fluid is more than about 7.5to about 8.5; and wherein hypochlorous acid is less than 1 Mol % of theFAC.
 35. The fluid of claim 34, wherein the fluid is not having a pHmodifier.
 36. (canceled)
 37. (canceled)
 38. The fluid of claim 34,wherein a concentration of the FAC at the point of use is about 10 g/lor less.
 39. The fluid of claim 34, wherein an operator exposure toinorganic chlorine species during usage of the solution at the point ofuse in a working shift of about 8 hours and 160 applications with eachapplication about 3 mins long, has no observed adverse effectconcentration (NOAEC) inhalation of about 0.5 mg/m³.
 40. The system ofclaim 1, wherein the solution at the point of use is free ofhypochlorous acid.
 41. The fluid of claim 34, wherein the fluid is freeof hypochlorous acid.
 42. The fluid of claim 34, wherein theconcentration of perchlorate is about 0.01 mg/L.
 43. The system of claim1, wherein the concentration of perchlorate is about 0.01 mg/L.